Lamination method to create a pre-press proof with a thermal mark

ABSTRACT

A method, a laminator ( 10 ), and a belt, for creating a pre-press proof ( 200 ) with a thermal mark ( 190 ) which comprises laminating a pre-laminate sheet ( 240 ) consisting of a first thermoplastic layer, and a first support layer ( 150 ) to a receiver stock ( 160 ); removing the first support layer ( 150 ) forming a pre-laminated receiver stock ( 350 ); creating an imaged receiver sheet ( 140 ) with a second print layer ( 308 ) and a second support layer ( 170 ); laminating the imaged receiver sheet ( 140 ) with the pre-laminated receiver stock ( 350 ) using an embossing belt ( 110 ) with an embossing mark  115;  and removing the second support layer ( 170 ) creating a pre-press proof with a thermal mark ( 230 ).

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This is a divisional of application Ser. No. 10/020,772, filedDec. 12, 2001.

FIELD OF THE INVENTION

[0002] The present invention relates to the art of color proofing, andin particular, to a method of preparing a pre-press proof with a thermalmark, such as by the use of pressure and heat to laminate mediatogether.

BACKGROUND OF THE INVENTION

[0003] Pre-press proofing is a procedure that is used primarily by theprinting industry for creating representative images of printedmaterial. In the printing industry pre-press proofs are used to checkfor color balance, control parameters, and other important image qualityrequirements, without the cost and time that is required to actuallyproduce printing plates, set up a printing press, and produce an exampleof a representative image, which would result in higher costs and a lossof profits that would ultimately be passes on to the customer.

[0004] To create a pre-press proof first an original image is separatedinto individual color separations or digital files. The original imageis scanned and separated into the three subtractive primaries and black.Typically a color scanner is used to create the color separations ordigital files and in some instances, more than four color separations ordigital files are used. Although there are several ways used in theprinting industry to create a pre-press proof from the color separationsor digital files they are generally one of three types. The first methodbeing a color overlay system that employs the representative image on aseparate base for each color, which are then overlaid to create apre-press proof. The second, a single integral sheet process in whichthe separate colors for the representative image is transferred one at atime by lamination onto a single base. Third, a digital method in whichthe representative image is produced directly onto a receiver stock, oronto an intermediate sheet then transferred by lamination onto areceiver stock from digital files.

[0005] The representative image to be laminated can be created on, butis not limited to, a commercially available Kodak image processingapparatus, depicted in commonly-assigned U.S. Pat. No. 5,268,708, whichdescribes an image processing apparatus having half-tone imagingcapabilities. The above-mentioned image processing apparatus is arrangedto form a representative image onto a sheet of print media in whichcolorant from a sheet of colorant donor material is transferred to theprint media, by applying a sufficient amount of thermal energy to thecolorant donor sheet material to form the representative image. Theimage processing apparatus is comprised generally of a material supplyassembly and a lathe bed scanning subsystem. The scanning subsystemincludes a lathe bed scanning frame, translation drive, translationstage member, printhead, imaging drum, and media exit transports.

[0006] The operation of the image processing apparatus comprises ofmetering a length of the print media (in roll form) from the materialsupply assembly. The print media is then measured and cut into sheetform of the required length and transported to the imaging drum,registered, wrapped around, and secured onto the imaging drum. Next, alength of colorant donor material (in roll form) is also metered out ofthe material supply assembly, then measured and cut into sheet form ofthe required length, transported to the imaging drum, and wrapped aroundthe imaging drum utilizing a load roller which is described in detail,in commonly-assigned U.S. Pat. No. 5,268,708, such that it is superposedin the desired registration with respect to the print media, which hasalready been secured to the imaging drum.

[0007] After the colorant donor sheet material is secured to theperiphery of the imaging drum the scanning subsystem or write engineprovides the imaging function. This image function is accomplished byretaining the print media and the colorant donor sheet material on theimaging drum while it is rotated past the printhead. The translationdrive traverses the printhead and translation stage member axially alongthe axis of the imaging drum, in coordinated motion with the rotatingimaging drum. These movements combine to produce the representativeimage on the print media.

[0008] Once the representative image has been formed on the print media,the colorant donor sheet material is then removed from the imaging drum.This is accomplished without disturbing the print media that is beneathit. The colorant donor sheet material is then transported out of theimage processing apparatus by means of the material exit transport.Additional colorant donor sheet materials featuring other desiredcolorants are sequentially superimposed with the print media on theimaging drum and then imaged onto the print media as previouslymentioned, until the representative image is completed on the printmedia. The representative image formed thereon is then unloaded from theimaging drum and transported by the receiver sheet material exittransport to an exit tray in the exterior of the image processingapparatus.

[0009] After a representative image has been formed on the print mediaas previously described it is transferred to a receiver stock such thatthe pre-press proof is representative of the intended image to beprinted on a printing press. A Kodak laminator as described in U.S. Pat.No. 5,478,434 can be used to bond or laminate the representative imageas a part of a pre-press proofing system. As additional references U.S.Pat. No. 5,203,942 describes a Kodak laminator that employs alamination/de-lamination system as applied to a drum laminator and U.S.Pat. No. 6,463,981 describes a Kodak laminator that employs endlessbelts incorporated into the lamination apparatus. For the purpose ofthis patent application the laminator described in U.S. Pat. No.6,463,981 will be used. It should be noted that the present inventiondescribed in this disclosure is not limited to a Kodak laminator or typeof laminator referenced above.

[0010] The receiver stock can be sheet-fed press printing stock,specially coated paper stock, or previously laminated stock. In thislatter case a sheet of pre-laminate, which has a pre-laminate supportlayer consisting of a suitable base material, optionally coated with areleasing material, and a print layer, is placed on top of a sheet orreceiver stock. This construction of multiple layers is a laminationsandwich, which is fed into the laminator. Once the lamination sandwichexits the laminator the pre-laminate support layer is peeled away fromthe now pre-laminated receiver stock. Any of the laminators referred toabove can be used to affect the transfer of the pre-laminate receivinglayer to the receiver stock.

[0011] Although the above described lamination method works well formost materials and both laser thermal and inkjet pre-press proofs thereexists a need for laminating a wider variety of pre-press proofs such asa pre-press proof with a thermal mark to appear to have a hologram orfoil effect used in the graphics packaging market.

SUMMARY OF THE INVENTION

[0012] The present invention relates to a method for forming a pre-pressproof with a thermal mark, a laminator for performing the stepsnecessary to create thermal marks on a pre-press proof, and a beltlaminator with embossing belt to be used to perform the embossing tocreate a pre-press proof with a thermal mark.

[0013] Specifically the method for creating a pre-press proof with athermal mark comprises the steps of creating a pre-press proof having animage formed thereon; embossing the surface of the pre-press proof bylaminating the pre-press proof with an embossing belt having a thermalmark thereon; and forming a pre-press proof with a thermal mark.

[0014] In an alternative embodiment, the invention relates to a methodfor creating a pre-press proof with a thermal mark which comprises thesteps of creating a pre-press proof having an image formed thereon;overlaying and laminating the pre-press proof with a plastic cover sheetforming an over laid pre-press proof; embossing the surface of theoverlaid pre-press proof by laminating the overlaid pre-press proof withan embossing belt having an image to form a thermal mark thereon; andforming a pre-press proof with a thermal mark.

[0015] In another alternative embodiment, the invention relates to amethod for creating a pre-press proof with a thermal mark whichcomprises creating an imaged receiver sheet having a support layer and aprint layer having an image formed on the print layer; laminating theimaged receiver sheet to a sheet of receiver stock; removing the supportlayer creating a pre-press proof; overlaying and laminating thepre-press proof with a glossing sheet; removing the glossing sheetforming a glossy pre-press proof; embossing the surface of the glossypre-press proof by laminating the glossy pre-press proof with anembossing belt having an image to form a thermal mark thereon; andforming a pre-press proof with a thermal mark.

[0016] In another alternative embodiment, the invention relates to amethod for creating a pre-press proof with a thermal mark whichcomprises laminating a pre-laminate sheet consisting of a first printlayer and a first support layer to a receiver stock; removing the firstsupport layer forming a pre-laminated receiver stock; creating an imagedreceiver sheet with a second support layer and a second print layerhaving an image formed on the second print layer; laminating the imagedreceiver sheet to the pre-laminated receiver stock; removing the secondsupport layer creating a pre-laminated pre-press proof; overlaying andlaminating a glossing sheet to the pre-laminated pre-press proof;removing the glossing sheet forming a pre-laminated glossy pre-pressproof; embossing the surface of the pre-laminated glossed pre-pressproof by laminating using an embossing belt having an image to form athermal mark thereon with the pre-laminated glossy pre-press proof; andforming a pre-press proof with a thermal mark.

[0017] A laminator for forming a pre-press proof with a thermal mark;having an identifying mark comprising; a first roller located on a firstside of a media passage; a second roller located on a second side of themedia passage so as to oppose the first roller, wherein a nip portion isdefined between the first and second rollers so as to apply pressure tomedia in the media passage which passes through the nip portion; andwherein at least one of the first and second rollers is a solid roller;and at least one embossing belt; and wherein the embossing belt forms athermal mark on a pre press proof upon passing of the pre-press proofthrough the laminator.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018]FIG. 1 is a perspective view showing a laminator known in therelated are used with the present invention.

[0019]FIG. 2 is a schematic right side elevation of the laminator ofFIG. 1.

[0020]FIG. 3 is a block diagram showing one embodiment of the method forproducing a pre-press proof with a thermal mark of the invention.

[0021]FIG. 4 is a block diagram showing another embodiment of the methodfor producing a pre-press proof with a thermal mark of the invention.

[0022]FIG. 5 is a block diagram showing another embodiment of the methodfor producing a pre-press proof with a thermal mark of the invention.

[0023]FIG. 6 is a block diagram showing another embodiment of the methodfor producing a pre-press proof with a thermal mark of the invention.

[0024]FIG. 7 is a perspective view of the belt according to the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

[0025] The present invention will be directed, in particular, toelements forming part of, or cooperating more directly with an apparatusin accordance with the present invention. It is to be understood thatelements not specifically shown or described may take various forms wellknown to those skilled in the art. For the sake of discussion, but notlimitation, the preferred embodiment of the present invention will beillustrated in relation to a laminating apparatus for making pre-pressproofs.

[0026] Referring to the drawings wherein like reference numeralsrepresent identical or corresponding parts throughout the several views.Referring to FIG. 1, there is shown perspective view of laminator 10 ofthe present invention having an entrance table 20, exit table 30,entrance slot 40, pressure lever 50, top cover 60, right side cover 70,left side cover 80, control panel 90, and lamination base 100.

[0027]FIG. 2 is a schematic right side elevation of the laminator 10showing embossing belts 110 with an embossing mark 115 (not shown)thereon for creating an identifying mark 390 (not shown) or thermal mark190 (not shown) on a pre-press proof 200 (not shown) along with theupper lamination roller 120 and lower lamination roller 130 which alongwith said embossing belts 110 convey media to be laminated through thelaminator 10. Media to be bonded or laminated passes between theembossing belts 110 and it should be noted, that only one of the beltsneeds to be an embossing belt 110. The embossing belt 110 and embossingmark 115 are shown in more detail in FIG. 7. Preferably the identifyingmark 390 is a thermal mark 190, a pressure mark 195, or both. Upperlamination roller 120 and lower lamination roller 130 provide heat andpressure to laminate the desired media together. This configuration withupper lamination roller 120 and lower lamination roller 130 is called a“straight-through” laminator. Although the illustrated embodiments showboth the upper lamination roller 120 and lower lamination roller 130 asheated pressure rollers, it also should be recognized that only one ofthe upper lamination roller 120 and lower lamination roller 130, couldbe heated. It is further recognized that both upper lamination roller120 and lower lamination roller 130 do not have to be heated for coldlamination applications.

[0028] The following methods are usable for forming a pre-press proof200 with a resolution of between 1000 and 4000 dpi, although in the mostpreferred embodiment, the high resolution is between 1200 and 3600 dpi.The image can be initially created on print media 380 with an inkjetprinter, laser printer, or any other printing method known in the art.

[0029] Referring to FIG. 3 a block diagram is shown outlining a methodfor producing a pre-press proof with a thermal mark 230, which comprisesthe steps of creating a pre-press proof 200 having an image 290 formedthereon; embossing the surface of the pre-press proof 200 by passing thepre-press proof 200 through laminator 10 with embossing belts 110 havingan embossing mark 115 to form a thermal mark 190 thereon; thus forming apre-press proof with a thermal mark 230.

[0030] Referring to FIG. 4 a block diagram is shown outlining analternative embodiment of the invention, the invention relates to amethod for creating a pre-press proof with a thermal mark 230 whichcomprises creating a pre-press proof 200 having an image 290 formedthereon; overlaying and laminating the pre-press proof 200 with aplastic cover sheet 320 embossing the surface of the plastic cover sheet320 with an embossing belt 115 having at least one embossing mark 115 toform a thermal mark 190 thereon; and forming an overlaid pre-press proofwith a thermal mark 330.

[0031] Referring to FIG. 5 a block diagram is shown outlining anotheralternative embodiment of the invention, which relates to a method forcreating a pre-press proof with a thermal mark 230 which comprisescreating an imaged receiver sheet 140 having a support layer 145comprising a release layer 270, aluminized layer 280 and a support base310 combinations there of or just a support base 310, and a print layer300 having an image 290 formed on print layer 300; laminating the imagedreceiver sheet 140 to a sheet of receiver stock 160; with laminator 10having at least one embossing belt 115 having at least one embossingmark 115 to form a thermal mark 190 thereon removing the support layer145; and forming a pre-press proof with a thermal mark 230.

[0032] Referring to FIG. 6 a block diagram is shown outlining anotheralternative embodiment of the invention, the invention relates to amethod for creating a pre-press proof with a thermal mark 230 whichcomprises the steps of: laminating a pre-laminate sheet 240 consistingof a first print layer 304, and a first support layer 150 having a firstrelease layer 274 and a first support base 314 or just a first supportbase 314, to a receiver stock 160; removing the first support layer 150forming a pre-laminated receiver stock 350; creating an imaged receiversheet 140 having a second support layer 170 comprising second releaselayer 278, aluminized layer 280 and a second support base 318combinations there of or just a second support base 318; laminating theimaged receiver sheet 140 to the pre-laminated receiver stock 350; bylaminating with an embossing belt 115 having at least one embossing mark115 to form a thermal mark 190 thereon; and removing the second support170 layer forming a pre-press proof with a thermal mark 230.

[0033] The invention contemplates the formation of a pre-press proofwith a thermal mark 230 with an image resolution of between 1000 and4000 dpi using the methods described above, although the more preferredresolution is expected to be between 1200 and 3600 dpi.

[0034] Additionally, it is contemplated that the image 290 formed onimaged receiver sheet 140 can be either monochrome or a multi-colored,that the image 290 of the imaged receiver sheet 140 can be an inkjetgenerated imaged, that the print layer 300, first print layer 304, andsecond print layer 308 have a thickness between 1 and 75 microns, andthat the glossing sheet 220 can be made from a sheet of plastic 360 orfrom a recycled support layer 370.

[0035] It is further contemplated that a pre-press proof with a thermalmark 230 could be formed on both side of a receiver stock 160simultaneously or one side at a time.

[0036] The invention also relates to a laminator 10 for forming apre-press proof 200 having an identifying mark 190 or thermal mark 390comprising an upper lamination roller located on a first side of a mediapassage; a lower lamination roller located on a second side of the mediapassage so as to oppose the upper roller, wherein a nip portion isdefined between the upper lamination and lower lamination rollers so asto apply pressure to media in the media passage which passes through thenip portion; wherein at least one of the upper lamination and lowerlamination rollers is a solid roller; at least one embossing belt 110;and wherein the embossing belt 110 creates an identifying mark 390 on apre press proof upon passing of the pre-press proof through thelaminator 10.

[0037] In an alternative embodiment, the laminator 10 is contemplated tohave at least one roller containing a heater element.

[0038] In still another embodiment, it is preferable that at least oneembossing belt 110 comprises a polyamide, such as nylon 6, 6, or nylon6, 10, or combinations of these materials. It is contemplated that twoembossing belts 110 could be used within the scope of this invention.

[0039] Finally, it is contemplated to be within the scope of thisembodiment of the invention, that the embossing belt 110 can be madefrom either a polyamide, a fluropolymer, a polyisocyanate, apolyphenylene sulfide, a polycarbonate, a copolymer of any of theforegoing, or combinations of these materials.

[0040]FIG. 8 is a perspective view of the embossing belt 110 accordingto the invention. It is contemplated that the embossing belt 110 has atleast one embossing mark 115, which can be at least one figure or designor possibly a number, or a series of numbers, or a character or seriesof characters and combinations thereof disposed on the surface of theembossing belt 110. A question mark would be an example of such a designor character to be disposed on the embossing belt 110. Exclamation marks“!” would be another example.

[0041] The invention has been described in detail with particularreference to certain preferred embodiments thereof, but it will beunderstood that variations and modifications can be effected within thescope of the invention.

PARTS LIST

[0042]10. Laminator

[0043]20. Entrance table

[0044]30. Exit table

[0045]40. Entrance slot

[0046]50. Pressure lever

[0047]60. Top cover

[0048]70. Right side cover

[0049]80. Left side cover

[0050]90. Control panel

[0051]100. Lamination base

[0052]110. Embossing belt

[0053]115. Embossing mark

[0054]120. Upper lamination roller

[0055]130. Lower lamination roller

[0056]140. Imaged receiver sheet

[0057]145. Support layer

[0058]150. First support layer

[0059]160. Receiver stock

[0060]170. Second support layer

[0061]190. Thermal mark

[0062]195. Pressure mark

[0063]200. Pre-press proof

[0064]220. Glossing sheet

[0065]230. Pre-press proof with a thermal mark

[0066]240. Pre-laminate sheet

[0067]250. Pre-laminated pre-press proof

[0068]260. Pre-laminated glossy pre-press proof

[0069]270. Release layer

[0070]274. First release layer

[0071]278. Second release layer

[0072]280. Aluminized layer

[0073]290. Image

[0074]300. Print layer

[0075]304. First print layer

[0076]308. Second print layer

[0077]310. Support base

[0078]314. First support base

[0079]318. Second support base

[0080]320. Plastic cover sheet

[0081]330. Overlaid pre-press proof with a thermal mark

[0082]340. Glossy pre-press proof

[0083]350. Pre-laminated receiver stock

[0084]360. Sheet of plastic

[0085]370. Recycled support layer

[0086]380. Print Media

[0087]390. Identifying mark

What is claimed is:
 1. A method for creating a pre-press proof with athermal mark consisting of: creating a pre-press proof having an imageformed thereon; and embossing the surface of said pre-press proof whilelaminating said pre-press proof with an endless embossing belt having anembossing mark to form a thermal mark thereon, wherein the image has aresolution of between 1000 dpi and 4000 dpi.
 2. A dual sided pre-pressproof having a thermal mark on both sides of said dual sided pre-pressproof by the method of claim
 1. 3. A method for creating a pre-pressproof with a thermal mark comprising: creating a pre-press proof havingan image formed thereon; overlaying and laminating said pre-press proofwith a plastic cover sheet; forming a thermal mark on the surface ofsaid plastic cover sheet by laminating with an embossing belt having anembossing mark to form a thermal mark thereon; and forming a pre-pressproof with a thermal mark.
 4. A pre-press proof with a thermal mark witha resolution of between 1000 dpi and 4000 dpi formed by the method ofclaim
 3. 5. A pre-press proof with a thermal mark with a resolution ofbetween 1200 dpi and 3600 dpi formed by the method of claim
 3. 6. A dualsided pre-press proof having a thermal mark on both sides of said dualsided pre-press proof by the method of claim
 3. 7. A method for creatinga pre-press proof with a thermal mark comprising: creating an imagedreceiver sheet having a support layer and a print layer having an imageformed on said print layer; laminating said imaged receiver sheet to asheet of receiver stock; forming a thermal mark on the surface of saidpre-press proof by laminating said glossy pre-press proof with anembossing belt having an embossing mark to create a thermal markthereon; removing said support layer creating a pre-press proof; forminga pre-press proof with a thermal mark; and wherein thermal mark with aresolution of between 1000 dpi and 4000 dpi.
 8. A pre-press proof with athermal mark with a resolution of between 1200 dpi and 3600 dpi formedby the method of claim
 7. 9. An embossed dual sided pre-press proofhaving both sides of said embossed dual sided pre-press proof embossedgenerated by the method of claim
 7. 10. A method for creating apre-press proof with a thermal mark comprising: laminating apre-laminate sheet consisting of a first print layer, and a firstsupport layer to a receiver stock; removing the first support layerforming a pre-laminated receiver stock; creating an imaged receiversheet with a second support layer and a second print layer having animage formed on said second print layer; laminating said imaged receiversheet to said pre-laminated receiver stock; embossing the pre-pressproof using an embossing belt with an image to form a thermal mark;removing said second support layer forming a pre-press proof with athermal mark; and wherein thermal mark with a resolution of between 1000dpi and 4000 dpi.
 11. A pre-press proof with a thermal mark with aresolution of between 1200 dpi and 3600 dpi formed by the method ofclaim
 10. 12. A dual sided pre-press proof having a thermal mark on bothsides of said dual sided pre-press proof generated by the method ofclaim
 10. 13. A laminator for forming a pre-press proof with a thermalmark having an identifying mark comprising: a first roller located on afirst side of a media passage; a second roller located on a second sideof said media passage so as to oppose said first roller, wherein a nipportion is defined between said first and second rollers so as to applypressure to media in said media passage which passes through said nipportion; wherein at least one of said first and second rollers is asolid roller and at least one embossing belt; wherein said embossingbelt creates a thermal mark on a pre press proof upon passing of saidpre-press proof through said laminator; and an embossed dual sidedpre-press proof has both sides of said embossed dual sided pre-pressproof embossed.
 14. A pre-press proof with a thermal mark with aresolution of between 1000 dpi and 4000 dpi formed by the method ofclaim
 13. 15. A pre-press proof with a thermal mark with a resolution ofbetween 1200 dpi and 3600 dpi formed by the method of claim 13.